CA3225343A1 - Process for preparing a coated paper article - Google Patents
Process for preparing a coated paper article Download PDFInfo
- Publication number
- CA3225343A1 CA3225343A1 CA3225343A CA3225343A CA3225343A1 CA 3225343 A1 CA3225343 A1 CA 3225343A1 CA 3225343 A CA3225343 A CA 3225343A CA 3225343 A CA3225343 A CA 3225343A CA 3225343 A1 CA3225343 A1 CA 3225343A1
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- CA
- Canada
- Prior art keywords
- weight percent
- structural units
- weight
- linear
- acrylate monomer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 238000004519 manufacturing process Methods 0.000 title description 4
- 239000000178 monomer Substances 0.000 claims abstract description 41
- 239000000123 paper Substances 0.000 claims abstract description 29
- 239000000203 mixture Substances 0.000 claims abstract description 28
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 claims abstract description 25
- 239000000758 substrate Substances 0.000 claims abstract description 22
- 229920000642 polymer Polymers 0.000 claims abstract description 20
- 238000000034 method Methods 0.000 claims abstract description 18
- 239000002245 particle Substances 0.000 claims abstract description 17
- 239000011087 paperboard Substances 0.000 claims abstract description 16
- 229920001567 vinyl ester resin Polymers 0.000 claims abstract description 15
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims abstract description 13
- 239000006185 dispersion Substances 0.000 claims abstract description 11
- 238000001035 drying Methods 0.000 claims abstract description 5
- 125000005250 alkyl acrylate group Chemical group 0.000 claims description 16
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical group CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 15
- 229920001577 copolymer Polymers 0.000 claims description 15
- -1 acetate anions Chemical class 0.000 claims description 11
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 claims description 9
- 239000007787 solid Substances 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 6
- 239000003795 chemical substances by application Substances 0.000 claims description 5
- SOGAXMICEFXMKE-UHFFFAOYSA-N Butylmethacrylate Chemical compound CCCCOC(=O)C(C)=C SOGAXMICEFXMKE-UHFFFAOYSA-N 0.000 claims description 4
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical group COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 claims description 4
- 238000005282 brightening Methods 0.000 claims description 4
- 230000003287 optical effect Effects 0.000 claims description 4
- 239000011230 binding agent Substances 0.000 claims description 3
- 239000004094 surface-active agent Substances 0.000 claims description 3
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 claims description 3
- GOXQRTZXKQZDDN-UHFFFAOYSA-N 2-Ethylhexyl acrylate Chemical compound CCCCC(CC)COC(=O)C=C GOXQRTZXKQZDDN-UHFFFAOYSA-N 0.000 claims description 2
- CFVWNXQPGQOHRJ-UHFFFAOYSA-N 2-methylpropyl prop-2-enoate Chemical compound CC(C)COC(=O)C=C CFVWNXQPGQOHRJ-UHFFFAOYSA-N 0.000 claims description 2
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 claims description 2
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 claims description 2
- 239000008199 coating composition Substances 0.000 claims description 2
- 239000003086 colorant Substances 0.000 claims description 2
- 239000003431 cross linking reagent Substances 0.000 claims description 2
- 239000002270 dispersing agent Substances 0.000 claims description 2
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 claims description 2
- 239000000049 pigment Substances 0.000 claims description 2
- 239000006254 rheological additive Substances 0.000 claims description 2
- 239000001993 wax Substances 0.000 claims description 2
- 230000004888 barrier function Effects 0.000 abstract description 13
- 238000000576 coating method Methods 0.000 abstract description 12
- 239000003921 oil Substances 0.000 abstract description 9
- 239000004519 grease Substances 0.000 abstract description 8
- 239000011248 coating agent Substances 0.000 abstract description 7
- 239000002480 mineral oil Substances 0.000 abstract description 3
- 235000010446 mineral oil Nutrition 0.000 abstract description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 16
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical class CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 13
- 229940048053 acrylate Drugs 0.000 description 13
- 239000000243 solution Substances 0.000 description 12
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 11
- 239000004816 latex Substances 0.000 description 9
- 229920000126 latex Polymers 0.000 description 9
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 6
- ROOXNKNUYICQNP-UHFFFAOYSA-N ammonium persulfate Chemical compound [NH4+].[NH4+].[O-]S(=O)(=O)OOS([O-])(=O)=O ROOXNKNUYICQNP-UHFFFAOYSA-N 0.000 description 6
- 230000007062 hydrolysis Effects 0.000 description 5
- 238000006460 hydrolysis reaction Methods 0.000 description 5
- 238000004806 packaging method and process Methods 0.000 description 5
- 229920002689 polyvinyl acetate Polymers 0.000 description 5
- 239000011118 polyvinyl acetate Substances 0.000 description 5
- 150000003839 salts Chemical class 0.000 description 5
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 4
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical compound CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 description 4
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 4
- 229920001909 styrene-acrylic polymer Polymers 0.000 description 4
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 3
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 description 3
- VMHLLURERBWHNL-UHFFFAOYSA-M Sodium acetate Chemical compound [Na+].CC([O-])=O VMHLLURERBWHNL-UHFFFAOYSA-M 0.000 description 3
- DWAQJAXMDSEUJJ-UHFFFAOYSA-M Sodium bisulfite Chemical compound [Na+].OS([O-])=O DWAQJAXMDSEUJJ-UHFFFAOYSA-M 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 229910001870 ammonium persulfate Inorganic materials 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 3
- 239000000839 emulsion Substances 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- 238000006116 polymerization reaction Methods 0.000 description 3
- 239000001632 sodium acetate Substances 0.000 description 3
- 235000017281 sodium acetate Nutrition 0.000 description 3
- 235000010267 sodium hydrogen sulphite Nutrition 0.000 description 3
- 239000011115 styrene butadiene Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 229920002554 vinyl polymer Polymers 0.000 description 3
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000002174 Styrene-butadiene Substances 0.000 description 2
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 2
- 239000004359 castor oil Substances 0.000 description 2
- 235000019438 castor oil Nutrition 0.000 description 2
- 230000001143 conditioned effect Effects 0.000 description 2
- 239000008367 deionised water Substances 0.000 description 2
- 229910021641 deionized water Inorganic materials 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 235000013305 food Nutrition 0.000 description 2
- ZEMPKEQAKRGZGQ-XOQCFJPHSA-N glycerol triricinoleate Natural products CCCCCC[C@@H](O)CC=CCCCCCCCC(=O)OC[C@@H](COC(=O)CCCCCCCC=CC[C@@H](O)CCCCCC)OC(=O)CCCCCCCC=CC[C@H](O)CCCCCC ZEMPKEQAKRGZGQ-XOQCFJPHSA-N 0.000 description 2
- 238000004128 high performance liquid chromatography Methods 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- SCVFZCLFOSHCOH-UHFFFAOYSA-M potassium acetate Chemical compound [K+].CC([O-])=O SCVFZCLFOSHCOH-UHFFFAOYSA-M 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 229920003048 styrene butadiene rubber Polymers 0.000 description 2
- CIHOLLKRGTVIJN-UHFFFAOYSA-N tert‐butyl hydroperoxide Chemical compound CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 2
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 2
- CHRJZRDFSQHIFI-UHFFFAOYSA-N 1,2-bis(ethenyl)benzene;styrene Chemical class C=CC1=CC=CC=C1.C=CC1=CC=CC=C1C=C CHRJZRDFSQHIFI-UHFFFAOYSA-N 0.000 description 1
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- PRAMZQXXPOLCIY-UHFFFAOYSA-N 2-(2-methylprop-2-enoyloxy)ethanesulfonic acid Chemical compound CC(=C)C(=O)OCCS(O)(=O)=O PRAMZQXXPOLCIY-UHFFFAOYSA-N 0.000 description 1
- JAHNSTQSQJOJLO-UHFFFAOYSA-N 2-(3-fluorophenyl)-1h-imidazole Chemical compound FC1=CC=CC(C=2NC=CN=2)=C1 JAHNSTQSQJOJLO-UHFFFAOYSA-N 0.000 description 1
- 229920000536 2-Acrylamido-2-methylpropane sulfonic acid Polymers 0.000 description 1
- XHZPRMZZQOIPDS-UHFFFAOYSA-N 2-Methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulfonic acid Chemical compound OS(=O)(=O)CC(C)(C)NC(=O)C=C XHZPRMZZQOIPDS-UHFFFAOYSA-N 0.000 description 1
- VSSGDAWBDKMCMI-UHFFFAOYSA-N 2-methyl-2-(2-methylprop-2-enoylamino)propane-1-sulfonic acid Chemical compound CC(=C)C(=O)NC(C)(C)CS(O)(=O)=O VSSGDAWBDKMCMI-UHFFFAOYSA-N 0.000 description 1
- GQTFHSAAODFMHB-UHFFFAOYSA-N 2-prop-2-enoyloxyethanesulfonic acid Chemical compound OS(=O)(=O)CCOC(=O)C=C GQTFHSAAODFMHB-UHFFFAOYSA-N 0.000 description 1
- KFNGWPXYNSJXOP-UHFFFAOYSA-N 3-(2-methylprop-2-enoyloxy)propane-1-sulfonic acid Chemical compound CC(=C)C(=O)OCCCS(O)(=O)=O KFNGWPXYNSJXOP-UHFFFAOYSA-N 0.000 description 1
- NYUTUWAFOUJLKI-UHFFFAOYSA-N 3-prop-2-enoyloxypropane-1-sulfonic acid Chemical compound OS(=O)(=O)CCCOC(=O)C=C NYUTUWAFOUJLKI-UHFFFAOYSA-N 0.000 description 1
- DBCAQXHNJOFNGC-UHFFFAOYSA-N 4-bromo-1,1,1-trifluorobutane Chemical compound FC(F)(F)CCCBr DBCAQXHNJOFNGC-UHFFFAOYSA-N 0.000 description 1
- USFZMSVCRYTOJT-UHFFFAOYSA-N Ammonium acetate Chemical compound N.CC(O)=O USFZMSVCRYTOJT-UHFFFAOYSA-N 0.000 description 1
- 239000005695 Ammonium acetate Substances 0.000 description 1
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 1
- 239000002033 PVDF binder Substances 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- 241000482268 Zea mays subsp. mays Species 0.000 description 1
- 229920006397 acrylic thermoplastic Polymers 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 235000019257 ammonium acetate Nutrition 0.000 description 1
- 229940043376 ammonium acetate Drugs 0.000 description 1
- 239000000908 ammonium hydroxide Substances 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- ZPOLOEWJWXZUSP-WAYWQWQTSA-N bis(prop-2-enyl) (z)-but-2-enedioate Chemical compound C=CCOC(=O)\C=C/C(=O)OCC=C ZPOLOEWJWXZUSP-WAYWQWQTSA-N 0.000 description 1
- QUDWYFHPNIMBFC-UHFFFAOYSA-N bis(prop-2-enyl) benzene-1,2-dicarboxylate Chemical compound C=CCOC(=O)C1=CC=CC=C1C(=O)OCC=C QUDWYFHPNIMBFC-UHFFFAOYSA-N 0.000 description 1
- FXBZWPXBAZFWIY-UHFFFAOYSA-N butyl prop-2-enoate;ethenyl acetate Chemical compound CC(=O)OC=C.CCCCOC(=O)C=C FXBZWPXBAZFWIY-UHFFFAOYSA-N 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 238000003776 cleavage reaction Methods 0.000 description 1
- LDHQCZJRKDOVOX-NSCUHMNNSA-N crotonic acid Chemical compound C\C=C\C(O)=O LDHQCZJRKDOVOX-NSCUHMNNSA-N 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000002845 discoloration Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000003995 emulsifying agent Substances 0.000 description 1
- 238000007720 emulsion polymerization reaction Methods 0.000 description 1
- MEGHWIAOTJPCHQ-UHFFFAOYSA-N ethenyl butanoate Chemical compound CCCC(=O)OC=C MEGHWIAOTJPCHQ-UHFFFAOYSA-N 0.000 description 1
- GLVVKKSPKXTQRB-UHFFFAOYSA-N ethenyl dodecanoate Chemical compound CCCCCCCCCCCC(=O)OC=C GLVVKKSPKXTQRB-UHFFFAOYSA-N 0.000 description 1
- QBDADGJLZNIRFQ-UHFFFAOYSA-N ethenyl octanoate Chemical compound CCCCCCCC(=O)OC=C QBDADGJLZNIRFQ-UHFFFAOYSA-N 0.000 description 1
- UIWXSTHGICQLQT-UHFFFAOYSA-N ethenyl propanoate Chemical compound CCC(=O)OC=C UIWXSTHGICQLQT-UHFFFAOYSA-N 0.000 description 1
- STVZJERGLQHEKB-UHFFFAOYSA-N ethylene glycol dimethacrylate Substances CC(=C)C(=O)OCCOC(=O)C(C)=C STVZJERGLQHEKB-UHFFFAOYSA-N 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000003000 extruded plastic Substances 0.000 description 1
- 238000007765 extrusion coating Methods 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- 230000003301 hydrolyzing effect Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- SURQXAFEQWPFPV-UHFFFAOYSA-L iron(2+) sulfate heptahydrate Chemical compound O.O.O.O.O.O.O.[Fe+2].[O-]S([O-])(=O)=O SURQXAFEQWPFPV-UHFFFAOYSA-L 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 1
- 235000011056 potassium acetate Nutrition 0.000 description 1
- FBCQUCJYYPMKRO-UHFFFAOYSA-N prop-2-enyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCC=C FBCQUCJYYPMKRO-UHFFFAOYSA-N 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 238000009738 saturating Methods 0.000 description 1
- 230000007017 scission Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- JVBXVOWTABLYPX-UHFFFAOYSA-L sodium dithionite Chemical compound [Na+].[Na+].[O-]S(=O)S([O-])=O JVBXVOWTABLYPX-UHFFFAOYSA-L 0.000 description 1
- BWYYYTVSBPRQCN-UHFFFAOYSA-M sodium;ethenesulfonate Chemical compound [Na+].[O-]S(=O)(=O)C=C BWYYYTVSBPRQCN-UHFFFAOYSA-M 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000013112 stability test Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000006228 supernatant Substances 0.000 description 1
- TXEYQDLBPFQVAA-UHFFFAOYSA-N tetrafluoromethane Chemical compound FC(F)(F)F TXEYQDLBPFQVAA-UHFFFAOYSA-N 0.000 description 1
- LDHQCZJRKDOVOX-UHFFFAOYSA-N trans-crotonic acid Natural products CC=CC(O)=O LDHQCZJRKDOVOX-UHFFFAOYSA-N 0.000 description 1
- NLVXSWCKKBEXTG-UHFFFAOYSA-N vinylsulfonic acid Chemical compound OS(=O)(=O)C=C NLVXSWCKKBEXTG-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/10—Coatings without pigments
- D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
- D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
- D21H21/16—Sizing or water-repelling agents
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/10—Packing paper
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Paper (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
The present invention relates to a method comprising the steps of applying to a paper or paperboard substrate an aqueous dispersion of polymer particles which comprise structural units of a vinyl ester, vinyl alcohol, and an acrylate monomer, then drying the composition. The method provides a coating that has oil and grease resistance, mineral oil barrier performance, and heat sealability.
Description
2 PROCESS FOR PREPARING A COATED PAPER ARTICLE
Background of the Invention The present invention relates to a process for preparing a coated paper article, more particularly, a paper or paperboard coated with a partially hydrolyzed poly(vinyl ester-co-acrylate). Paper and paperboard are increasingly used in packaging applications as sustainable alternatives to plastic packaging due to the renewability and biodegradability of paper. In many applications, paper and paperboard need to be coated with a barrier material to reduce the penetration of oil, grease, moisture, and oxygen through these substrates. Achieving oil and grease resistance (OGR) is essential for paper and paperboard packages used in food service applications such as sandwich wraps, popcorn bags, and bakery boxes. Barrier coatings designed for these applications are typically used to block the oil from saturating the underlying paper substrate, which can alter the material's appearance and decrease the structural integrity of the packaging.
Conventional OGR papers are treated with perfluorocarbon additives, which, while highly effective barrier materials, are under intensive regulatory scrutiny. Extruded plastic films such as polyethylene have also been used to coat paper and paperboard and have been found to exhibit good barrier performance. However, extrusion coatings require off-machine application and create films that are unnecessarily thick, thereby increasing cost and limiting the repulpability and recyclability of these coated paper products.
Aqueous dispersion coatings are environmentally friendly alternatives to fluorochemical and polyethylene coatings and they can be applied at low coat weights to enable improved repulpability and recyclability of the paper packages. Synthetic latexes based on acrylics, styrene-acrylic (SA), and styrene-butadiene (SB) polymers are the most commonly used materials in barrier coating applications. These compositions can provide excellent OGR to the paper and paperboard substrates but are often deficient in other coating properties that are important to the production and application of paper products, such as flexibility (or foldability), block resistance, and heat sealability. Poly(vinyl acetate) (PVAc) dispersions are a class of synthetic latex that have been traditionally used in coating compositions in the paper industry.
These latexes provide advantages such as low cost, heat and light stability, glueability, and blister resistance over SA and SB type binders. However, PVAc does not provide good barrier properties required for packaging applications. It would therefore be an advance in the art of coated paper and paperboard articles to develop a cost-effective and environmentally friendly article with acceptable oil and grease resistance and barrier properties.
Summary of the Invention The present invention addresses a need in the art by providing a method comprising the steps of applying a composition onto a paper or paperboard substrate, then drying the composition to form a substrate superposed with a film having a dry coat weight in the range of from 1 g/m2 to 20 g/m2;
wherein the composition comprises an aqueous dispersion of copolymer particles comprising, based on the weight of the copolymer particles, a) from 40 to 96 weight percent structural units of a vinyl ester; b) from 2 to 50 weight percent structural units of vinyl alcohol; and c) from 0.5 to 30 weight percent structural units of a Ci-Cs linear or branched alkyl acrylate monomer;
wherein the aqueous dispersion has a solids content in the range of from 15 to 60 weight percent;
and wherein at least 50 weight percent of the film comprises one or more polymers, wherein at least 50 weight percent of the one or more polymers comprises structural units of the vinyl ester, vinyl alcohol, and the acryl ate monomer.
The present invention is useful for preparing an article with oil and grease resistance, mineral oil barrier performance, and heat sealability.
Detailed Description of the Invention The present invention is a method comprising the steps of applying a composition onto a paper or paperboard substrate, then drying the composition to form a substrate superposed with a film having a dry coat weight in the range of from 1 g/m2 to 20 g/m2;
wherein the composition comprises an aqueous dispersion of copolymer particles comprising, based on the weight of the copolymer particles, a) from 40 to 96 weight percent structural units of a vinyl ester; b) from 2 to 50 weight percent structural units of vinyl alcohol; and c) from 0.5 to 30 weight percent structural units of a C1-C8 linear or branched alkyl acrylate monomer;
wherein the aqueous dispersion has a solids content in the range of from 15 to 60 weight percent;
and wherein at least 50 weight percent of the film comprises one or more polymers, wherein at least 50 weight percent of the one or more polymers comprises structural units of the vinyl ester, vinyl alcohol, and the acrylate monomer.
As used herein, the term "structural units" of the named monomer refers to the remnant of the monomer after polymerization. For example, a structural unit of vinyl alcohol is as illustrated:
HO
where the dotted lines represent the points of attachment of the structural unit to the polymer backbone.
The composition used to make the coated paper or paperboard substrate is advantageously prepared in two steps: In a first step, a vinyl ester and a Ci-C8 linear or branched alkyl acrylate are copolymerized under emulsion polymerization conditions to form a dispersion of poly(vinyl ester-co-acrylate) copolymer particles; then the copolymer is partially hydrolyzed with a base to form a dispersion of polymer particles comprising structural units of the vinyl ester, vinyl alcohol, and the acrylate. Thus, a structural unit of vinyl alcohol need not require vinyl alcohol as a starting material.
Additional monomers may be used in the polymerization reaction including carboxylic acid monomers and sulfonic acid monomer or salts thereof. Examples of suitable carboxylic acid monomers include acrylic acid, methacrylic acid, fumaric acid, itaconic acid, crotonic acid, and maleic acid; examples of suitable sulfonic acid monomers include sulfoethyl acrylate, sulfoethyl methacrylate, sulfopropyl acrylate, sulfopropyl methacrylate, vinyl sulfonic acid, 2-acrylamido-2-methyl propanesulfonic acid, and 2-methacrylamido-2-methyl propanesulfonic acid, as well as salts thereof. The concentration of structural units of the carboxylic acid monomer is typically in the range of from 0.1 to 5 weight percent, based on the weight of the polymer particles; the concentration of structural units of the sulfonic acid monomer is also typically in the range of from 0.1 to 5 weight percent, based on the weight of the polymer particles.
Multiethylenically unsaturated monomers may also be used in the polymerization reaction, typically at a concentration in the range of from 0.1 to 5 weight percent, based on the weight of the monomers. Examples of suitable multiethylenically unsaturated monomers include allyl methacrylate, ethylene glycol dimethacrylate, diallyl maleate, and diallyl phthalate.
As used herein, the term "acrylate monomers" refers to acrylate or methacrylate monomers.
Suitable Ci-Cs linear or branched alkyl acrylate monomers (alkyl acrylate monomers) include methyl acrylate, methyl methacrylate, ethyl acrylate, n-butyl acrylate, n-butyl methacrylate, isobutyl acrylate, t-butyl acrylate, and 2-ethylhexyl acrylate.
Background of the Invention The present invention relates to a process for preparing a coated paper article, more particularly, a paper or paperboard coated with a partially hydrolyzed poly(vinyl ester-co-acrylate). Paper and paperboard are increasingly used in packaging applications as sustainable alternatives to plastic packaging due to the renewability and biodegradability of paper. In many applications, paper and paperboard need to be coated with a barrier material to reduce the penetration of oil, grease, moisture, and oxygen through these substrates. Achieving oil and grease resistance (OGR) is essential for paper and paperboard packages used in food service applications such as sandwich wraps, popcorn bags, and bakery boxes. Barrier coatings designed for these applications are typically used to block the oil from saturating the underlying paper substrate, which can alter the material's appearance and decrease the structural integrity of the packaging.
Conventional OGR papers are treated with perfluorocarbon additives, which, while highly effective barrier materials, are under intensive regulatory scrutiny. Extruded plastic films such as polyethylene have also been used to coat paper and paperboard and have been found to exhibit good barrier performance. However, extrusion coatings require off-machine application and create films that are unnecessarily thick, thereby increasing cost and limiting the repulpability and recyclability of these coated paper products.
Aqueous dispersion coatings are environmentally friendly alternatives to fluorochemical and polyethylene coatings and they can be applied at low coat weights to enable improved repulpability and recyclability of the paper packages. Synthetic latexes based on acrylics, styrene-acrylic (SA), and styrene-butadiene (SB) polymers are the most commonly used materials in barrier coating applications. These compositions can provide excellent OGR to the paper and paperboard substrates but are often deficient in other coating properties that are important to the production and application of paper products, such as flexibility (or foldability), block resistance, and heat sealability. Poly(vinyl acetate) (PVAc) dispersions are a class of synthetic latex that have been traditionally used in coating compositions in the paper industry.
These latexes provide advantages such as low cost, heat and light stability, glueability, and blister resistance over SA and SB type binders. However, PVAc does not provide good barrier properties required for packaging applications. It would therefore be an advance in the art of coated paper and paperboard articles to develop a cost-effective and environmentally friendly article with acceptable oil and grease resistance and barrier properties.
Summary of the Invention The present invention addresses a need in the art by providing a method comprising the steps of applying a composition onto a paper or paperboard substrate, then drying the composition to form a substrate superposed with a film having a dry coat weight in the range of from 1 g/m2 to 20 g/m2;
wherein the composition comprises an aqueous dispersion of copolymer particles comprising, based on the weight of the copolymer particles, a) from 40 to 96 weight percent structural units of a vinyl ester; b) from 2 to 50 weight percent structural units of vinyl alcohol; and c) from 0.5 to 30 weight percent structural units of a Ci-Cs linear or branched alkyl acrylate monomer;
wherein the aqueous dispersion has a solids content in the range of from 15 to 60 weight percent;
and wherein at least 50 weight percent of the film comprises one or more polymers, wherein at least 50 weight percent of the one or more polymers comprises structural units of the vinyl ester, vinyl alcohol, and the acryl ate monomer.
The present invention is useful for preparing an article with oil and grease resistance, mineral oil barrier performance, and heat sealability.
Detailed Description of the Invention The present invention is a method comprising the steps of applying a composition onto a paper or paperboard substrate, then drying the composition to form a substrate superposed with a film having a dry coat weight in the range of from 1 g/m2 to 20 g/m2;
wherein the composition comprises an aqueous dispersion of copolymer particles comprising, based on the weight of the copolymer particles, a) from 40 to 96 weight percent structural units of a vinyl ester; b) from 2 to 50 weight percent structural units of vinyl alcohol; and c) from 0.5 to 30 weight percent structural units of a C1-C8 linear or branched alkyl acrylate monomer;
wherein the aqueous dispersion has a solids content in the range of from 15 to 60 weight percent;
and wherein at least 50 weight percent of the film comprises one or more polymers, wherein at least 50 weight percent of the one or more polymers comprises structural units of the vinyl ester, vinyl alcohol, and the acrylate monomer.
As used herein, the term "structural units" of the named monomer refers to the remnant of the monomer after polymerization. For example, a structural unit of vinyl alcohol is as illustrated:
HO
where the dotted lines represent the points of attachment of the structural unit to the polymer backbone.
The composition used to make the coated paper or paperboard substrate is advantageously prepared in two steps: In a first step, a vinyl ester and a Ci-C8 linear or branched alkyl acrylate are copolymerized under emulsion polymerization conditions to form a dispersion of poly(vinyl ester-co-acrylate) copolymer particles; then the copolymer is partially hydrolyzed with a base to form a dispersion of polymer particles comprising structural units of the vinyl ester, vinyl alcohol, and the acrylate. Thus, a structural unit of vinyl alcohol need not require vinyl alcohol as a starting material.
Additional monomers may be used in the polymerization reaction including carboxylic acid monomers and sulfonic acid monomer or salts thereof. Examples of suitable carboxylic acid monomers include acrylic acid, methacrylic acid, fumaric acid, itaconic acid, crotonic acid, and maleic acid; examples of suitable sulfonic acid monomers include sulfoethyl acrylate, sulfoethyl methacrylate, sulfopropyl acrylate, sulfopropyl methacrylate, vinyl sulfonic acid, 2-acrylamido-2-methyl propanesulfonic acid, and 2-methacrylamido-2-methyl propanesulfonic acid, as well as salts thereof. The concentration of structural units of the carboxylic acid monomer is typically in the range of from 0.1 to 5 weight percent, based on the weight of the polymer particles; the concentration of structural units of the sulfonic acid monomer is also typically in the range of from 0.1 to 5 weight percent, based on the weight of the polymer particles.
Multiethylenically unsaturated monomers may also be used in the polymerization reaction, typically at a concentration in the range of from 0.1 to 5 weight percent, based on the weight of the monomers. Examples of suitable multiethylenically unsaturated monomers include allyl methacrylate, ethylene glycol dimethacrylate, diallyl maleate, and diallyl phthalate.
As used herein, the term "acrylate monomers" refers to acrylate or methacrylate monomers.
Suitable Ci-Cs linear or branched alkyl acrylate monomers (alkyl acrylate monomers) include methyl acrylate, methyl methacrylate, ethyl acrylate, n-butyl acrylate, n-butyl methacrylate, isobutyl acrylate, t-butyl acrylate, and 2-ethylhexyl acrylate.
3 Examples of vinyl esters include vinyl acetate, vinyl propionate, vinyl butyrate, vinyl octanoate, vinyl laurate, and vinyl versatate, with vinyl acetate being preferred. The concentration of structural units of the vinyl ester in the composition used to prepare the coated substrate is in the range of from 40 to 96 weight percent, based on the weight of the polymer particles; the concentration of structural units of vinyl alcohol is in the range of from 2, or from 5, or from 8 weight percent, to 50, or to 40 weight percent, based on the weight of the polymer particles.
The concentration of structural units of the alkyl acrylate monomer is in the range of from 0.5, or from 1, to 30, or to 25 weight percent, but has been found to be optimal over a narrower range at higher concentrations of structural units of vinyl alcohol; more particularly, the concentration of structural units of the alkyl acrylate monomer is in the range of from 3, or from 4, to 20 weight percent when the concentration of structural units of vinyl alcohol is in the range of from 13, or from 20 weight percent, to 40 weight percent.
When the composition used to make the coated substrate is prepared by hydrolyzing a copolymer of the vinyl ester and the acrylate monomer under basic conditions, the composition further comprises a salt of a carboxylic acid, which is formed as a hydrolysis byproduct. The salt may be removed from the composition if desired. Where the vinyl ester is vinyl acetate, the composition may comprise an acetate anion at a concentration in the range of from 5 or from 8 weight percent, to 40 or to 35 weight percent, based on the weight of the acetate anion and the structural units of vinyl acetate, vinyl alcohol, the acrylate monomer. Sodium acetate, potassium acetate, and ammonium acetate arc examples of salts of acetic acid, with sodium acetate being most common.
The composition used to prepare the coated substrate may include additional materials such as surfactants, binders, waxes, defoamers, dispersants, rheology modifiers, pigments, crosslinking agents, and colorants. Although it is possible to include an optical brightening agent in the composition used in the process of the present invention, it is best not to use such agents since the end use application for the prepared coated paper or paperboard is most commonly in the field of food packaging. The concentration of an optical brightening agent is therefore preferably less than 5 weight percent, more preferably less than 1 weight percent, and most preferably 0 weight percent, based on the weight of the composition.
The article of the present invention is advantageously prepared by applying the aqueous composition to a paper or paperboard substrate in a sufficient amount to achieve the desired coat weight, then drying the composition at an advanced temperature until the water is removed. The
The concentration of structural units of the alkyl acrylate monomer is in the range of from 0.5, or from 1, to 30, or to 25 weight percent, but has been found to be optimal over a narrower range at higher concentrations of structural units of vinyl alcohol; more particularly, the concentration of structural units of the alkyl acrylate monomer is in the range of from 3, or from 4, to 20 weight percent when the concentration of structural units of vinyl alcohol is in the range of from 13, or from 20 weight percent, to 40 weight percent.
When the composition used to make the coated substrate is prepared by hydrolyzing a copolymer of the vinyl ester and the acrylate monomer under basic conditions, the composition further comprises a salt of a carboxylic acid, which is formed as a hydrolysis byproduct. The salt may be removed from the composition if desired. Where the vinyl ester is vinyl acetate, the composition may comprise an acetate anion at a concentration in the range of from 5 or from 8 weight percent, to 40 or to 35 weight percent, based on the weight of the acetate anion and the structural units of vinyl acetate, vinyl alcohol, the acrylate monomer. Sodium acetate, potassium acetate, and ammonium acetate arc examples of salts of acetic acid, with sodium acetate being most common.
The composition used to prepare the coated substrate may include additional materials such as surfactants, binders, waxes, defoamers, dispersants, rheology modifiers, pigments, crosslinking agents, and colorants. Although it is possible to include an optical brightening agent in the composition used in the process of the present invention, it is best not to use such agents since the end use application for the prepared coated paper or paperboard is most commonly in the field of food packaging. The concentration of an optical brightening agent is therefore preferably less than 5 weight percent, more preferably less than 1 weight percent, and most preferably 0 weight percent, based on the weight of the composition.
The article of the present invention is advantageously prepared by applying the aqueous composition to a paper or paperboard substrate in a sufficient amount to achieve the desired coat weight, then drying the composition at an advanced temperature until the water is removed. The
4 film comprises one or more polymers wherein at least 50, or at least 65, or at least 75, or at least 85, or at least 95 weight percent of the one or more polymers comprises a copolymer of the vinyl ester, vinyl alcohol, and the acrylate monomer, based on the weight of the film. The coating may comprise other polymers such as acrylic, styrene-butadiene, and styrene-acrylic polymers.
Alternatively, the coating comprises from 60 or from 65 weight percent, to 95 or to 92 weight percent structural units of preferably vinyl acetate, vinyl alcohol, and the acrylate monomer and from 5 or from 8 weight percent, to 40 or to 30 weight percent of an acetate anion, based on the weight of the acetate anions an the structural units of preferably vinyl acetate, vinyl alcohol, and the acrylate monomer. The method of the present invention provides a coated paper or paperboard substrate with excellent oil and grease barrier resistance.
Examples Intermediate Example 1 ¨ Preparation of a Vinyl Acetate-Butyl Acrylate Latex Deionized water (783.0 g) was charged into a 5-L, 4-neck round bottom flask and heated to 60 C under N2. In a separate vessel, a monomer emulsion containing deionized water (451.0 g), sodium vinyl sulfonate (32.0 g, 25% in water), sodium acetate (4.0 g), TERGITOLTm 15-S-40 Surfactant (A Trademark of The Dow Chemical Company or its Affiliates, 22.9 g, 70% in water), Disponi] FES 993 Emulsifier (106.6 g, 30% in water), glacial acrylic acid (8.0 g), butyl acrylate (32.0 g), and vinyl acetate (1552.0 g) was prepared. A portion of the monomer emulsion (44.2 g) was added to the reactor with rinsing (16.0 g water), followed by the addition of ammonium persulfate (1.5 g in 8.0 g water) with rinsing (8.0 g water) and then a solution of sodium bisulfite (0.3 g), ferrous sulfate heptahydrate (17 mg) and sodium dithionite (0.6 g) in 8.0 g water with rinsing (8.0 water). After a 2-min hold, the remainder of the monomer emulsion was fed into the reactor over 120 min. A solution of ammonium persulfate (4.9 g) and t-butyl hydroperoxide (2.0 g) in 120.0 g water, and a solution of sodium bisulfite (3.2 g in 120.0 g water) were simultaneously fed into the reactor over 130 min at temperature in the range of 64-66 C. Upon completion of all feeds and rinses, the reactor was cooled to 60 C whereupon a solution of ammonium persulfate (0.5 g) and t-butyl hydroperoxide (1.7 g) in 48.0 g water, and a solution of sodium bisulfite (2.7 g in 48.0 g water) were simultaneously fed over 30 min. The reactor was then cooled to room temperature and ammonium hydroxide (6.9 g, 28 wt%) was added dropwise to raise the pH to 6.5-7.5. Solids content was found to be 48 wt. %.
Alternatively, the coating comprises from 60 or from 65 weight percent, to 95 or to 92 weight percent structural units of preferably vinyl acetate, vinyl alcohol, and the acrylate monomer and from 5 or from 8 weight percent, to 40 or to 30 weight percent of an acetate anion, based on the weight of the acetate anions an the structural units of preferably vinyl acetate, vinyl alcohol, and the acrylate monomer. The method of the present invention provides a coated paper or paperboard substrate with excellent oil and grease barrier resistance.
Examples Intermediate Example 1 ¨ Preparation of a Vinyl Acetate-Butyl Acrylate Latex Deionized water (783.0 g) was charged into a 5-L, 4-neck round bottom flask and heated to 60 C under N2. In a separate vessel, a monomer emulsion containing deionized water (451.0 g), sodium vinyl sulfonate (32.0 g, 25% in water), sodium acetate (4.0 g), TERGITOLTm 15-S-40 Surfactant (A Trademark of The Dow Chemical Company or its Affiliates, 22.9 g, 70% in water), Disponi] FES 993 Emulsifier (106.6 g, 30% in water), glacial acrylic acid (8.0 g), butyl acrylate (32.0 g), and vinyl acetate (1552.0 g) was prepared. A portion of the monomer emulsion (44.2 g) was added to the reactor with rinsing (16.0 g water), followed by the addition of ammonium persulfate (1.5 g in 8.0 g water) with rinsing (8.0 g water) and then a solution of sodium bisulfite (0.3 g), ferrous sulfate heptahydrate (17 mg) and sodium dithionite (0.6 g) in 8.0 g water with rinsing (8.0 water). After a 2-min hold, the remainder of the monomer emulsion was fed into the reactor over 120 min. A solution of ammonium persulfate (4.9 g) and t-butyl hydroperoxide (2.0 g) in 120.0 g water, and a solution of sodium bisulfite (3.2 g in 120.0 g water) were simultaneously fed into the reactor over 130 min at temperature in the range of 64-66 C. Upon completion of all feeds and rinses, the reactor was cooled to 60 C whereupon a solution of ammonium persulfate (0.5 g) and t-butyl hydroperoxide (1.7 g) in 48.0 g water, and a solution of sodium bisulfite (2.7 g in 48.0 g water) were simultaneously fed over 30 min. The reactor was then cooled to room temperature and ammonium hydroxide (6.9 g, 28 wt%) was added dropwise to raise the pH to 6.5-7.5. Solids content was found to be 48 wt. %.
5 Intermediate Example 2 - Partial Hydrolysis of a Copolymer of Vinyl Acetate and Butyl Acrylate A portion of the latex of the Intermediate 1 latex (300 g, -48% solids) was placed in a jar at room temperature, whereupon sodium hydroxide solution (10 wt% in water) was added dropwise to the stirred latex over 1 h to achieve the target hydrolysis level.
The pH of the partially hydrolyzed latex was in the range of 9.0-10.0 and the solids was in the range of 27%
and 46% depending on the degree of hydrolysis. The sample was stored at room temperature and the degree of hydrolysis was determined by HPLC analysis of the acetic acid generated via the cleavage of acetate group as described in the following section.
High Performance Liquid Chromatographic (HPLC) Analysis of Acetic Acid HPLC analysis was performed using an Agilent 1100 Series HPLC equipped with a Phenomenex Rezex ROA Organic Acid H+ 240 x 4.6 mm column (8 lam particle size, 8% cross-linked sulfonated styrenedivinylbenzene), Phenomenex Carbo-H4 column guard, and UV
detector operating at a wavelength of 210 nm. The hydrolyzed latex samples were diluted tenfold and centrifuged at 100,000 rpm for 15 mm, after which time the supernatant was filtered through a 0.45 1.tm PVDF syringe filter. The sample injection volume was 5 pL
and separations were performed with 2.5 mM phosphoric acid at a flow rate of 0.4 mL/min and a column temperature of 35 C. The instrument was externally calibrated from 50 to 10,000 ppm using acetic acid.
The stability of the hydrolyzed latexes was evaluated and illustrated in Table 1. The weight percentages of structural units of vinyl acetate (VA), butyl acrylate (BA), and vinyl alcohol are based on the weight of the polymer and the weight percent of the acetate anion (Ac0-) are based on the weight of total solids of the hydrolyzed copolymer and the Ac0-.
Samples that remained unsolidified after 6 months passed the stability test, and samples that solidified within 3 months failed the test.
The pH of the partially hydrolyzed latex was in the range of 9.0-10.0 and the solids was in the range of 27%
and 46% depending on the degree of hydrolysis. The sample was stored at room temperature and the degree of hydrolysis was determined by HPLC analysis of the acetic acid generated via the cleavage of acetate group as described in the following section.
High Performance Liquid Chromatographic (HPLC) Analysis of Acetic Acid HPLC analysis was performed using an Agilent 1100 Series HPLC equipped with a Phenomenex Rezex ROA Organic Acid H+ 240 x 4.6 mm column (8 lam particle size, 8% cross-linked sulfonated styrenedivinylbenzene), Phenomenex Carbo-H4 column guard, and UV
detector operating at a wavelength of 210 nm. The hydrolyzed latex samples were diluted tenfold and centrifuged at 100,000 rpm for 15 mm, after which time the supernatant was filtered through a 0.45 1.tm PVDF syringe filter. The sample injection volume was 5 pL
and separations were performed with 2.5 mM phosphoric acid at a flow rate of 0.4 mL/min and a column temperature of 35 C. The instrument was externally calibrated from 50 to 10,000 ppm using acetic acid.
The stability of the hydrolyzed latexes was evaluated and illustrated in Table 1. The weight percentages of structural units of vinyl acetate (VA), butyl acrylate (BA), and vinyl alcohol are based on the weight of the polymer and the weight percent of the acetate anion (Ac0-) are based on the weight of total solids of the hydrolyzed copolymer and the Ac0-.
Samples that remained unsolidified after 6 months passed the stability test, and samples that solidified within 3 months failed the test.
6 Table 1 - Stability of Partially Hydrolyzed Polyvinyl Acetate Latexes Example BA VA Vinyl alcohol Ac0- Stability (wt%) (wt.%) (wt%) (wt%) Comp. Ex. 1 0 87.7 11.2 13.1 Fail Comp. Ex 2 10 89 0 0 Pass Ex. 1 2.2 85.7 11.0 12.8 Pass Ex. 2 6.6 81.8 10.5 12.3 Pass Ex. 3 7.3 68.2 23.3 23.8 Pass Ex. 4 11.0 78.0 10.0 11.8 Pass Ex. 5 12.1 64.6 22.0 22.8 Pass Ex. 6 13.5 48.2 37.0 33.1 Pass Ex. 7 21.7 68.5 8.8 10.5 Pass The data show the importance of inclusion of an acrylate to achieve latex colloidal stability.
Preparation of the Coated Substrate Example 1 to 7 latexes were applied to UPM Brilliant Pro paper (basis weight:
62 g/m2) in the machine direction using an automated coater (K Control Coater) equipped with various wire wound rods to achieve dry coat weights of 5 0.3 g/m2. Samples were dried at 100 C for 2 min. The coated paper was conditioned in a temperature-controlled room for at least 1 h in accordance with TAPPI 402 standards.
3M Kit Test Coated paper samples were tested for oil and grease resistance using TAPPI
method T559-cm-12 with an extended range of kit scores_ Kit solutions composed of castor oil, toluene, and heptane in varying ratios were applied dropwise to the coated substrate, allowed to sit for 15 s, then wiped away. Any occurrence of solvent breakthrough or substrate discoloration was classified as a failure for that Kit solution. The Kit score for a given sample was assigned using the number of the highest (most aggressive) Kit solution that passed on that coated substrate. In the TAPPI method, Kit scores range from 1 to 12 for the compositions of the Kit solutions.
Additionally, more aggressive solutions were prepared to assign Kit values up to 16, as illustrated in Table 2 below. Each sample was tested in duplicate.
Preparation of the Coated Substrate Example 1 to 7 latexes were applied to UPM Brilliant Pro paper (basis weight:
62 g/m2) in the machine direction using an automated coater (K Control Coater) equipped with various wire wound rods to achieve dry coat weights of 5 0.3 g/m2. Samples were dried at 100 C for 2 min. The coated paper was conditioned in a temperature-controlled room for at least 1 h in accordance with TAPPI 402 standards.
3M Kit Test Coated paper samples were tested for oil and grease resistance using TAPPI
method T559-cm-12 with an extended range of kit scores_ Kit solutions composed of castor oil, toluene, and heptane in varying ratios were applied dropwise to the coated substrate, allowed to sit for 15 s, then wiped away. Any occurrence of solvent breakthrough or substrate discoloration was classified as a failure for that Kit solution. The Kit score for a given sample was assigned using the number of the highest (most aggressive) Kit solution that passed on that coated substrate. In the TAPPI method, Kit scores range from 1 to 12 for the compositions of the Kit solutions.
Additionally, more aggressive solutions were prepared to assign Kit values up to 16, as illustrated in Table 2 below. Each sample was tested in duplicate.
7 Table 2 - Kit Testing Kit Value Kit solution composition Wt% Castor Oil Wt % Toluene Wt % Heptane 1 100.00 0.00 0.00 2 91.91 4.57 3.52 3 83.46 9.35 7.19 4 74.65 14.33 11.03 65.43 1954. 15.03 6 55.79 24.99 19.23 7 45.69 30.69 23.62
8 35.10 36.68 28.23
9 23.98 42.96 33.06 12.30 49.56 38.14 11 0.00 56.51 43.49 12 0_00 51_53 48_47 13 0.00 46.42 53.58 14 0.00 41.17 58.83 0.00 35.77 64.23 16 0.00 30.22 69.78 Hexane Vapor Transmission Rate (HVTR) Coated paper samples were conditioned in a fume hood overnight before conducting the experiment. Coated paper substrates were cut into 2.5" circles. Reagent grade n-hexane (5 g) was placed into a permeability cup using a pipette. The sample was placed coating side down on top of the rubber gasket and the lid tightened to clamp the sample to the permeability cup. The initial mass of the permeability cup with sample attached was recorded, and the cups were weighed again after 24 h. To calculate the hexane vapor transmission rate, the weight after 24 h was subtracted from the initial weight and then divided by 0.000212 (area of exposed sample).
The calculation provides a hexane vapor transmission rate in units of g/m2-day.
Heat Sealability The ability to heat seal the coated paper was evaluated using a single-phase Sentinel Laboratory Heat Staler. Coated samples were cut to 2" x 4" rectangles and placed coated side to coated side in the clamp of the heat sealer at a temperature of 190 C and pressure of 100 psi for 0.5 s. After the substrate was cooled to room temperature, the two sheets were separated.
Samples that separated with fiber tear were deemed a pass, while samples that separated without fiber tear were deemed a fail. Samples were tested in duplicate. Table 3 illustrates the barrier performance of the various coatings.
Table 3 ¨ Barrier Performance of Polyvinyl Acetate Latexes Example Flat Kit HVTR Heat Seal Comp. Ex 2 8 46 Fail Ex. 1 16 12 Pass Ex. 2 16 10 Pass Ex. 3 15 23 Pass Ex. 4 16 8 Pass Ex. 5 15 15 Pass Ex. 6 14 13 Pass Ex. 7 15 27 Pass The data show improved oil and grease resistance, mineral oil barrier (lower HVTR), and heat sealability for coatings prepared from partially hydrolyzed copolymers, as compared to the coating prepared from a latex composition that was not partially hydrolyzed.
The calculation provides a hexane vapor transmission rate in units of g/m2-day.
Heat Sealability The ability to heat seal the coated paper was evaluated using a single-phase Sentinel Laboratory Heat Staler. Coated samples were cut to 2" x 4" rectangles and placed coated side to coated side in the clamp of the heat sealer at a temperature of 190 C and pressure of 100 psi for 0.5 s. After the substrate was cooled to room temperature, the two sheets were separated.
Samples that separated with fiber tear were deemed a pass, while samples that separated without fiber tear were deemed a fail. Samples were tested in duplicate. Table 3 illustrates the barrier performance of the various coatings.
Table 3 ¨ Barrier Performance of Polyvinyl Acetate Latexes Example Flat Kit HVTR Heat Seal Comp. Ex 2 8 46 Fail Ex. 1 16 12 Pass Ex. 2 16 10 Pass Ex. 3 15 23 Pass Ex. 4 16 8 Pass Ex. 5 15 15 Pass Ex. 6 14 13 Pass Ex. 7 15 27 Pass The data show improved oil and grease resistance, mineral oil barrier (lower HVTR), and heat sealability for coatings prepared from partially hydrolyzed copolymers, as compared to the coating prepared from a latex composition that was not partially hydrolyzed.
Claims (10)
1. A method comprising the steps of applying a composition onto a paper or paperboard substrate, then drying the composition to form a substrate superposed with a film having a dry coat weight in the range of from 1 g/m2 to 20 g/m2;
wherein the composition comprises an aqueous dispersion of copolymer particles comprising, based on the weight of the copolymer particles, a) from 40 to 96 weight percent structural units of a vinyl ester; 1)) from 2 to 50 weight percent structural units of vinyl alcohol; and c) from 0.5 to 30 weight percent structural units of a Ci -C8 linear or branched alkyl acrylate monomer;
wherein the aqueous dispersion has a solids content in the range of from 15 to 60 weight percent;
and wherein at least 50 weight percent of the film comprises one or more polymers, wherein at least 50 weight percent of the one or more polymers comprises structural units of the vinyl ester, vinyl alcohol, and the acrylate monomer.
wherein the composition comprises an aqueous dispersion of copolymer particles comprising, based on the weight of the copolymer particles, a) from 40 to 96 weight percent structural units of a vinyl ester; 1)) from 2 to 50 weight percent structural units of vinyl alcohol; and c) from 0.5 to 30 weight percent structural units of a Ci -C8 linear or branched alkyl acrylate monomer;
wherein the aqueous dispersion has a solids content in the range of from 15 to 60 weight percent;
and wherein at least 50 weight percent of the film comprises one or more polymers, wherein at least 50 weight percent of the one or more polymers comprises structural units of the vinyl ester, vinyl alcohol, and the acrylate monomer.
2. The method of Claim 1 wherein the C i-C8 linear or branched alkyl acrylate monomer is selected from the group consisting of methyl acrylate, methyl methacrylate, ethyl acrylate, n-butyl acrylate, n-butyl methacrylate, isobutyl acrylate, t-butyl acrylate, and 2-ethylhexyl acrylate; and the vinyl ester is vinyl acetate.
3. The method of Claim 2 wherein the copolymer particles comprise, based on the weight of the copolymer particles, from 8 to 50 weight percent structural units of vinyl alcohol; and from 1 to 25 weight percent structural units of the Ci-C8 linear or branched alkyl acrylate monomer.
4. The method of Claim 2 wherein the concentration of structural units of the Ci-C8 linear or branched alkyl acrylate monomer is in the range of from 3 to 20 weight percent when the concentration of structural units of vinyl alcohol is in the range of from 13 to 40 weight percent.
5. The method of Claim 3 wherein the Ci-Cs linear or branched alkyl acrylate monomer is n-butyl acrylate.
6. The method of any of Claims 2 to 5 wherein at least 65 weight percent of the one or more polymers comprises structural units of vinyl acetate, vinyl alcohol, and the Ci-C8 linear or branched alkyl acrylate monomer.
7. The method of Claim 2 wherein the coating composition comprises a) from 60 to 95 weight percent of the structural units of vinyl acetate, vinyl alcohol, and the C i-C8 linear or branched alkyl acrylate monomer; and b) from 5 to 40 weight percent of an acetate anions; wherein the weight percent ranges are based on the weight of the acetate anions and the structural units of vinyl acetate, vinyl alcohol, and the Ci-C8 linear or branched alkyl acrylate monomer.
8. The method of either of Claim 4 or 7 wherein Ci -Cs linear or branched alkyl acrylate monomer is n-butyl acrylate.
9. The method of Claim 1 wherein the composition further comprises at least one additional material selected from the group consisting of surfactants, binders, defoamers, waxes, dispersants, rheology modifiers, pigments, crosslinking agents, and colorants;
and less than weight percent of an optical brightening agent, based on the weight of the composition.
and less than weight percent of an optical brightening agent, based on the weight of the composition.
10. The method of Claim 1 wherein the composition further comprises less than 1 weight percent of an optical brightening agent, based on the weight of the polymer particles.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US202163225602P | 2021-07-26 | 2021-07-26 | |
US63/225,602 | 2021-07-26 | ||
PCT/US2022/034204 WO2023009242A1 (en) | 2021-07-26 | 2022-06-21 | Process for preparing a coated paper article |
Publications (1)
Publication Number | Publication Date |
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CA3225343A1 true CA3225343A1 (en) | 2023-02-02 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CA3225343A Pending CA3225343A1 (en) | 2021-07-26 | 2022-06-21 | Process for preparing a coated paper article |
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KR (1) | KR20240035591A (en) |
CN (1) | CN117597488A (en) |
CA (1) | CA3225343A1 (en) |
WO (1) | WO2023009242A1 (en) |
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US20070232743A1 (en) * | 2006-03-30 | 2007-10-04 | Mario Laviolette | Method of forming a vapor impermeable, repulpable coating for a cellulosic substrate and a coating composition for the same |
EP2182113A1 (en) * | 2008-10-30 | 2010-05-05 | Kuraray Europe GmbH | Method of curtain coating substrates without using tensides |
EP2894253B1 (en) * | 2012-09-04 | 2017-12-27 | Kuraray Co., Ltd. | Greaseproof paper having excellent folding resistance |
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2022
- 2022-06-21 CN CN202280045109.XA patent/CN117597488A/en active Pending
- 2022-06-21 CA CA3225343A patent/CA3225343A1/en active Pending
- 2022-06-21 WO PCT/US2022/034204 patent/WO2023009242A1/en active Application Filing
- 2022-06-21 KR KR1020247005659A patent/KR20240035591A/en unknown
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KR20240035591A (en) | 2024-03-15 |
WO2023009242A1 (en) | 2023-02-02 |
CN117597488A (en) | 2024-02-23 |
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